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ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

Recommended Maintenance Intervals


Continuous Duty - Reciprocating Compressors
Ariel compressors, like all industrial equipment, require maintenance. The severity of compressor
service directly influences the frequency and amount of maintenance needed. Below are
recommended intervals for inspections and replacements to help determine appropriate intervals for
a given compressor application. Careful documentation of inspection results is critical to establish
whether recommended intervals are adequate or require more or less frequency.
NOTE: For intermittent duty service, see ER-8.2.2.
As part of your maintenance program, Ariel recommends:

Consistent adherence to safety policies, procedures, and equipment warning labels.


Daily operational checks.
Routine trending and review of operational parameters.
Routine oil analysis and trending.
Detailed records of all maintenance.
To avoid contamination, keep all covers in place where access is not required. Use lint free cloths
or paper towels during internal maintenance.
CAUTION: Gas compressors are complicated and dangerous pieces of equipment. Only
fully trained operators and mechanics familiar with unit operation should attempt any
maintenance. Read and thoroughly understand your manual and always wear appropriate personal protection equipment during maintenance.
Never adjust any fastener torques while the unit is operating or pressurized.
To prevent serious personal injury or death, verify driver or compressor cylinder gas
pressure cannot turn compressor crankshaft during maintenance. For engine-driven
compressors, either remove the center coupling or lock the flywheel; for electric motordriven compressors, either detach the driver from the compressor or lock out the driver
switch gear. Before any maintenance or component removal, relieve all pressure from
compressor cylinders. See packager information to completely vent the system or call
the packager for assistance. After maintenance, purge the entire system with gas prior to
operation to avoid a potentially explosive air/gas mixture.

REV

15

DESCRIPTION

Page 5, #11, 2nd Bullet: Removed per inch of rod diameter.

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REV 15

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EC

DATE

11

015652

11-25-08

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EC

DATE

10

015308

10-10-08

15

017908

10-31-11

014795

11-19-07

14

017889

10-26-11

014236

3-19-07

13

015759

9-9-11

013283

1-16-06

12

015364

9-13-10

ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

Initial Maintenance
Comply with Ariel Packager Standards and the compressor Start Up Check List. Adhere to all items
before and after start-up. After running a new, relocated, reconfigured, or overhauled compressor for
24 hours, shut down, vent the gas system, and perform the following maintenance:
0.012
Angular TIR Limit, in., max.

1. Perform a hot coupling alignment check within 30 minutes of


shutdown; bar driver shaft to
packager recommendations.

0.010
0.008

To ensure parallel and concentric drive train alignment, posi0.006


tion connected equipment so
0.004
the total indicator reading (TIR)
is as close to zero as possible
0.002
on the coupling hub faces and
outside diameters at normal
0.000
operating temperature. Do not
0
10
20
30
40
50
exceed 0.005 inches (0.13 mm)
Hub Diameter, in.
on the face and outside diameFIGURE 1 Angular Coupling-Hub Face Alignment TIR Limits
ter, except for outside diameters
above 17 in. (43 cm) where the
angular face TIR limit is 0 1 (0.0167).
Hub O.D. > 17 in. x 0.00029 = angular coupling-hub face TIR, in. max.
Hub O.D. > 43 cm x 0.0029 = angular coupling-hub face TIR, mm max.)
Center the coupling between the driver and compressor. It must not thrust or force the crankshaft
against either thrust face.
For cold alignment, account for the difference in thermal TABLE 1 Compressor Thermal
growth height between the compressor and driver. Table Height Growth Predictions
1 lists compressor centerline height change based on 6.5
Thermal Height
x 10-6/F (11.7 x 10-6/C) and a differential temperature of
Frame
Growth
100F (55.6C). Obtain driver thermal growth predictions
Model
Inches
(mm)
from the driver manufacturer.
2. At hot alignment check, adjust discharge bottle supports
and head end supports, if applicable.
NOTE: To avoid cylinder distortion, lift discharge bottles only 0.003 to 0.005 inch using the supports.
3. Check fastener torque on gas nozzle flanges, valve caps,
cylinder heads, piston rod packing flanges, and crosshead guide to frame bolting, if applicable. See Maintenance and Repair Manual or Ariel document ER-63 for
correct torques. After the first week or 150 hours, recheck fastener torques.

JGM:N:P:Q

0.006 (0.15)

JG:A:I

0.007 (0.18)

JGR:W:J

0.008 (0.20)

JGH:E:K:T

0.011 (0.28)

JGC:D

0.014 (0.36)

JGZ:U, KBZ:U

0.016 (0.41)

JGB:V

0.020 (0.51)

KBB:V

0.018 (0.46)

4. Repeat torque check after the first month or 650 hours; re-check fasteners that turn after the second month or 1300 hours. If loosening persists, consult your packager or Ariel for probable cause
and recommended correction.

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ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

Daily Maintenance
1. Log and trend the following:
Operating RPM, gas pressure and temperatures - determine if the unit is operating within
design parameters and expectations.
NOTE: Verify high and low pressure shutdowns are set as close as practical to normal
operating conditions. Set points must protect the machine from exceeding compressor
limits.
Bearing temperatures - if the unit is equipped with main bearing temperature sensors.
Frame oil pressure - at operating temperature (190F (88C) max. inlet oil temperature), it
should be 50 to 60 psig (3.5 to 4.2 barg) at the filter gauges. If pressure falls below 50 psig,
shut down the compressor then determine and correct the cause.
Frame inlet oil temperature.
Oil filter differential pressure - differential pressure exceeding the filter change value indicates a
need for a filter change. See filter information plate on top cover or Maintenance and Repair
Manual for procedure.
2. Check frame oil level. It should be about mid-level in the sight glass and free of foam when running. If not, determine and correct the cause. Do not overfill. Check oil makeup tank for sufficient
oil supply. For dry sump frames, check the package sump oil level.
3. Check force feed lubricator box oil level. It should be full to the overflow line.
4. Log and trend packing vent temperature and check crosshead guide vents for leakage.
5. If applicable, check suction valve unloader actuator vents for leakage.
6. If applicable, check clearance pocket vents for leakage.
7. Verify the high discharge gas temperature shutdown is set to within 10% or as close as practical
above the normal operating discharge temperature. Do not exceed the maximum discharge temperature shutdown setting for the application.
8. Log and trend valve cap temperatures.
9. Check lubricator block cycle time. See lubricator box data plate for correct cycle time. Contaminated gas may require a shorter cycle time. Check lube sheet for units not running at rated
speed.
10. Check for gas, oil, and coolant leaks.
CAUTION: Do not attempt to repair leaks while the unit is operating or pressurized.
11. Check for unusual noises or vibrations.
12. See packager documentation for additional recommended checks, i.e. scrubber liquid levels,
dump valve operation, cooler louver positions, etc.

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REV 15

ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

Monthly Maintenance
1. Perform all Daily maintenance.
2. Verify safety shutdown functionality.
3. Sample frame oil and send it to a reputable lubricant lab for analysis. See Ariel Packager Standards (ER-56.06) for a list of what an oil analysis should provide. If analysis results indicate
increasing levels of lead, tin, or copper particles in the oil, shut down unit. Remove frame top
cover and crosshead guide side covers. Visually inspect for debris. Do not disassemble further
without good reason. If debris indicates, replace affected parts, then change the oil, oil filter, and
clean the oil strainer with a suitable solvent.
4. Check and log cylinder clearance devices in use and their settings.

Six-Month (4,000 Hour) Maintenance


1. Perform all Daily and Monthly maintenance.
2. Shut down unit and allow sufficient time for components to cool.
3. Drain and replace force feed lubricator box oil.
4. Clean sintered element in the small oil filter on the force feed lubrication system now or at every
main oil filter change. Use a suitable solvent
5. Change oil filter. See top cover filter information plate or Maintenance and Repair Manual for procedure).
NOTE: On replaceable element style filters, drain the canister completely before removing
the element.
NOTE: Replaceable filter elements have a finite shelf life. Check the Install by date on
the filter element before installation. Inspect elements for cleanliness and damage. Do not
install dirty or damaged elements.
6. Change oil. Extremely dirty environments, oil supplier recommendations, or oil analysis may dictate a different oil change interval. Follow these steps:
a. Drain oil from frame, associated piping, and oil cooler.
b. Clean oil strainer with suitable solvent.
c. Open frame top cover and crosshead guide side covers. Visually inspect for debris. Do not
disassemble further without good reason. If debris indicates, replace affected parts, then
change the oil and filter and clean the strainer with a suitable solvent.
d. Refill frame with fresh, clean oil.
7. Check cylinder lubrication. See Maintenance and Repair Manual for procedure.
8. Re-tighten hold down nuts to proper torque. Inspect for frame twist or bending to verify main
bearing bore alignment. See Ariel document ER-82 for flatness and soft foot requirements.
9. Perform a coupling alignment (see "Initial Maintenance" above).

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REV 15

ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

One-Year (8,000 Hour) Maintenance


1. Perform all Daily, Monthly, and Six-Month maintenance.
2. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of multi-purpose grease using a
standard hand pump grease gun. Turn VVCP adjustment handle all the way in and all the way
out to lubricate the threads. Measure or count turns to return the handle to its orginal position.
3. Open force feed lubricator box and visually inspect pump followers, cams, and gears for wear.
4. Pressure test distribution blocks. See Maintenance and Repair Manual for procedure.
5. Measure, log, and trend the following:
Main bearing, connecting rod bearing, and crankshaft jack and thrust clearances.
NOTE: Clearance trends along with oil analysis and crankcase visual inspection can indicate the need for bearing replacement. Contact Ariel for original assembly clearances.
Crosshead to guide clearances.
Piston rod run out.
See Maintenance and Repair Manual for procedures. If any of the above items are outside limits
listed in the Maintenance and Repair Manual, replace the affected parts.
6. Remove valves and valve gaskets:
a. Visually inspect valve pockets for damage. Verify all old valve seat gaskets are removed.
b. Have a qualified valve repair shop disassemble, visually inspect, and refurbish the valves
where needed. Provide the valve repair shop an Ariel torque chart and valve service guide.
c. Visually inspect cylinder gas passages and clean them of all debris.
7. If applicable, visually inspect suction valve unloader actuator stems for damage or wear. Visually
inspect stem seals for damage or wear and confirm that the actuator moves freely.
8. If applicable, visually inspect valve pneumatic clearance pockets for damage or wear (seating
surface and stems/stem seals). Confirm that actuator moves freely.
9. Inspect cylinder bores for damage or wear. Replace the cylinder body or restore the bore if any of
the following conditions exist:
Bore surface blemishes or gouges.
Bore out of round more than 0.001 inch per inch of bore diameter (0.001 mm/mm) or tapered.
10. Inspect piston rings and wearband:
a. Measure and log piston ring condition, end gap, and side clearance.
b. Replace rings that are damaged or outside limits listed in Maintenance and Repair Manual.
c. When replacing rings, re-measure and log ring side clearance to check for groove wear.
d. Measure and log radial projection of wear band.
11. Inspect piston rods for damage and excessive wear. Replace rod if any of these conditions exist:

Gouges or scratches on the rod.


Under size more than 0.005 inch (0.13 mm).
Out of round more than 0.001 inch (0.03 mm) per inch of rod diameter.
Tapered more than 0.002 inch (0.05 mm) per inch of rod diameter.

12. Rebuild piston rod pressure packing cases. See Maintenance and Repair Manual for procedure.
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REV 15

ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

13. Re-install valves, retainers, and valve caps using new valve gaskets and valve cap o-rings/seals.
Use proper installation techniques and torque procedures for valve caps.
14. Check and re-calibrate all required instrumentation.
15. Clean crankcase breather filter with suitable solvent.
16. Check and, if needed, adjust drive chains. See ER-74 for procedure.
17. If the compressor is equipped with crankcase over-pressure relief valves, visually inspect and
exercise valves to manufacturer recommendations.
18. Check fastener torques of gas nozzle flange, valve cap, piston rod packing, crosshead pin
through bolt, crosshead guide to frame, crosshead guide to cylinder, cylinder mounting flange to
forged steel cylinder, distance piece to cylinder, distance piece to crosshead guide, and tandem
cylinder to cylinder.

Two-Year (16,000 Hour) Maintenance


1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.
2. Rebuild oil wiper cases.
3. If applicable, use new piston and stem seals to rebuild actuators on suction valve unloaders and
fix volume pneumatic pockets. Replace piston stem assemblies where stem is damaged or worn.
4. Check auxiliary end chain drive for undercut sprocket teeth and chain for excessive stretching.
Replace as required.

Three-Year (24,000 Hour) Maintenance


1. Perform all Daily, Monthly, Six-Month, and One-Year maintenance.
2. Replace non-ELP connecting rod bearings for JGJ:E:T:C:D:U:Z:B:V and KBB:V. See Maintenance and Repair manual for procedure.
NOTE: Main and connecting rod bearing wear and replacement intervals are heavily
dependent on many factors including speed, load, oil temperature, oil cleanliness, and oil
quality. Depending on the severity of service, the bearing maintenance interval may be
longer or shorter.

Four-Year (32,000 Hour) Maintenance


1. Perform all Daily, Monthly, Six-Month, One-Year, and Two-Year maintenance.
2. Remove crosshead pins. Measure and log crosshead pin to crosshead pin bore and connecting
rod bushing bore clearances. Check the crosshead pin end caps and through bolt for wear.
Replace if needed.
3. Check for bushing wear in the auxiliary end drive chain tightener.
4. Check for ring groove wear in pistons.

PAGE 6 OF 7

REV 15

ER-8.2

ENGINEERING REFERENCE

The contents of this document are proprietary and confidential. They are the
property of Ariel Corporation and may not be disclosed, reproduced, or used for
manufacture in part or in whole without written permission from Ariel Corporation.

Six-Year (48,000 Hour) Maintenance


1. Perform all Daily, Monthly, Six-Month, One-Year, Two-Year, and Three-Year maintenance.
2. Replace lubricator distribution blocks.
3. Replace crosshead and connecting rod bushings. See Maintenance and Repair Manual for procedures.
4. Replace connecting rod bearings. See Maintenance and Repair Manual for procedure.
5. Replace main bearings. See Maintenance and Repair manual for procedure.

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ER-8.2